MAGNETROL 44-606 Tuffy Liquid Level Controls with Pneumatic Switch User Manual
- June 4, 2024
- MAGNETROL
Table of Contents
MAGNETROL 44-606 Tuffy Liquid Level Controls with Pneumatic Switch
Read this Manual Before Installing
This manual provides information on the Tuffy Liquid Level Control with
Pneumatic Switch. It is important that all instructions are read carefully and
followed in sequence. Detailed installation and wiring instructions are
included in this manual.
Conventions Used in this Manual
Certain conventions are used in this manual to convey specific types of
information. General technical material, support data, and safety information
are presented in narrative form. The following styles are used for notes,
cautions, and warnings.
Notes
Notes contain information that augments or clarifies an operating step. Notes
do not normally contain actions. They follow the procedural steps to which
they refer.
Cautions
Cautions alert the technician to special conditions that could injure
personnel, damage equipment, or reduce a component’s mechanical integrity.
Cautions are also used to alert the technician to unsafe practices or the need
for special protective equipment or specific materials. In this manual, a
caution box indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury.
Warnings
Warnings identify potentially dangerous situations or serious hazards. In this
manual, a warning indicates an imminently hazardous situation which, if not
avoided, could result in serious injury or death.
Safety Messages
Follow all standard industry procedures for servicing elec-trical equipment
when working with or around high voltage. Always shut off the power supply
before touching any components.
WARNING!
Explosion hazard. Do not connect or dis-connect equipment unless power has
been switched off or the area is known to be non-hazardous.
Warranty
All Magnetron mechanical level and flow controls are war-ranted free of
defects in materials or workmanship for three full years from the date of
original factory shipment.
If returned within the warranty period; and, upon factory inspection of the
control, the cause of the claim is determined to be covered under the
warranty; then, Magnetron will repair or replace the control at no cost to the
purchaser (or owner) other than transportation.
Magnetron shall not be liable for misapplication, labor claims, direct or
consequential damage or expense arising from the installation or use of
equipment. There are no other warranties expressed or implied, except special
written warranties covering some Magnetron products.
Quality Assurance
The quality assurance system in place at Magnetron guarantees the highest
level of quality throughout the company. Magnetron is committed to providing
full customer satisfaction both in quality products and quality service.
Magnetrol’s quality assurance system is registered to ISO 9001 affirming its
commitment to known international quality standards providing the strongest
assurance of product/service quality available.
Copyright © 2021 AMETEK Magnetron USA, LLC. All rights reserved.
Performance specifications are effective with date of issue and are subject to
change without notice. Magnetron® reserves the right to make changes to the
product described in this manual at any time without notice. Magnetron makes
no warranty with respect to the accuracy of the information in this manual.
Installation
This section provides detailed procedures for properly installing the Tuffy
Liquid Level Control.
Caution:
If equipment is used in a manner not specified by manufacturer, protection
provided by equipment may be impaired.
Unpacking
Unpack the instrument carefully. Inspect all units for dam-age. Report any concealed damage to the carrier within 24 hours. Check the contents of the packing slip and report any discrepancies to Magnetron. Check the nameplate model number to be sure it agrees with the packing slip and pur-chase order. Check and record the serial number for future reference when ordering parts.
Before You Begin
Site Preparation
-
Ensure that the length and inside diameter of the mounting nozzle are sized correctly to allow for switch actuation at design levels.
-
Ensure that the mounting nozzle or coupling is within 3°of horizontal. If mounting the Tuffy in an external cage, ensure that the cage is mounted within 3° of horizontal and that the top/bottom piping is within 3° of vertical in all directions.
-
Ensure that the area is free of metallic particles which might be attracted to the magnet holder/counterbalance and interfere with the function of the Tuffy.
Equipment and Tools
No special equipment or tools are required to install the Tuffy Liquid
Level Switch. The following items are recommended:
- Wrenches, flange gaskets and flange bolting appropriate for process connection(s).
- Pipe wrench
- Level
Mounting
The pneumatic Tuffy® Liquid Level Switch is available with a 2″ NPT mounting
bushing, a variety of flange mountings and external cages for mounting outside
of the vessel.
Mounting an NPT Tuffy®
- Apply either Teflon® tape or Petrolatum to the mounting threads to prevent galling.
- Engage the 2″ NPT by hand to avoid damaging threads.
- Using a pipe wrench, rotate the unit clockwise until threads are tight in mounting. Ensure that the serial number plate is on top.
Caution: The pneumatic Tuffy must be installed with the serial number
plate on top to ensure correct switching action.
Mounting a Tuffy with Flange
- Have proper flange bolting and gasket on hand.
- Carefully align mounting flange with the vessel mounting flange.
- Ensure that the flange gasket is seated properly. Install flange bolts and nuts.
- Tighten alternating flange bolts in a star pattern.
- Install Tuffy into 2″ NPT of mounting flange
Caution:
Operation of all buoyancy type level devices should be done in such a way as
to minimize the action of dynamic forces on the float or displacer sensing
element. Good practice for reducing the likelihood of damage to the control is
to equal-ize pressure across the device very slowly.
Mounting External Cage Tuffy
A typical Tuffy® external cage installation.
- Install cage so that tapping’s are within 3° of vertical in all directions. Check installation with a level.
- Mount cage as close to vessel as possible, to provide more accurate level in cage. Long pipe runs may result in cooler, denser liquid than that in the vessel and cause inaccurate level in the Tuffy cage.
- Use pipe of sufficient size and strength to support the control. If necessary, provide a hanger or stand to help support the weight of the cage.
- All piping should be straight and free of low spots or pockets. Lower liquid line should drain toward vessel and upper line toward Tuffy cage.
- Shut-off valves are recommended for installation between the vessel and the cage assembly.
- Once external cage is mounted, install pneumatic Tuffy into cage۔
Airline Connections
- Inlet air should be filtered with a 5 micron or finer filter. This will extend the life of the valve mechanism.
- Connect the inlet air line to the 1⁄4″ NPT connection for either air inlet A or air inlet B, depending on the valve action desired .Inlet air pressure should be between 0–200 psig. Refer to Figure 1 for location of air inlets.
- Connect outlet air line to the 1⁄4″ NPT connection on the bottom of the valve. This air outlet is designated with a “C”.
- If 3-way function is used, attach the exhaust air line to the appropriate 1⁄4″ NPT connection based on valve action .
Reference Information
Description
Tuffy liquid level switches are designed for horizontal mounting in a tank or vessel through threaded or flanged pipe connections. Standard models are equipped with a three-port/two-position valve actuated by a magnetically actuated pivoted cam mechanism. This instruction manual covers Tuffy level controls which have pneumatic switches. For Tuffy controls with electric switches, please consult Bulletin 44-607.
Theory of Operation
At a “low operating level” of liquid in a tank or vessel , the float moves the
magnet upward and into the field of the switch mechanism magnet.
Low Level Operation—Direct Acting
As a result, the magnets
repel causing the pivot arm and valve plunger to move so that air is allowed
to pass from air inlet A to air outlet C. As liquid level rises, the float
moves the magnet downward until the switch mechanism magnet reverses position,
allowing the valve plunger to move so that air is allowed to pass from air
inlet B to air outlet C .
High Level Operation—Direct Acting
For direct acting low
level operation, air inlet A is closed off when liquid level increases.
Conversely, for high level operation, air inlet B is closed off when liquid
level recedes.
For reverse acting operation, air inlet A is used for high level and air inlet
B is used for low level. Plug the air inlet that is not in use to prevent
foreign materials from entering.
Preventive Maintenance
Periodic inspections are a necessary means to keep your Magnetron level
control in good working order. This control is a safety device to protect the
valuable equipment it serves. A systematic program of preventive maintenance
should be implemented when the control is placed into service. Based on
utilizing a preventative maintenance program and observing the following
section on “what to avoid”, your Tuffy will provide reliable protection of
your capital equipment for many years.
WHAT TO AVOID
- Use only the 2″ wrench flats to install or remove the unit. Refer to Figure 1. Use of any other surface could change the calibration. The valve body is calibrated at the factory and locked in place.
- NEVER attempt to make adjustments without reading the instructions carefully. When in doubt, consult the factory or your local representative.
- NEVER use in systems which have excess iron particles in the solution. The magnet at the counterweight end of the float can attract the particles which could cause the float rod to jam.
Troubleshooting
If Tuffy fails to shut off or turn on inlet air:
- Check float for full range of travel; clicking of mechanism should be heard.
- If the complete Tuffy mechanism operates properly when removed from service, check to be certain that liquid is entering the storage tank or vessel. A valve may be closed or a pipe line clogged.
- If the float is determined to be filled with liquid or is collapsed, the entire level switch must be replaced. Do not attempt to repair the float.
- The factory calibration setting should not require any adjustment in the field. Check to see that the unit is installed properly with the serial number tag positioned on the top of the unit. If the unit is still not operating correctly, please contact the factory.
NOTE: When in doubt about the condition or performance of a control, please contact the factory for assistance.
Specifications
Mechanical Specifications
**Parts
**
Physical
Model Numbers
ASSURED QUALITY & SERVICE COST LESS
Service Policy
- Owners of Magnetron may request the return of a control or any part of a control for complete rebuilding or replacement. They will be rebuilt or replaced promptly. Controls returned under our service policy must be returned by Prepaid transportation. Magnetron will repair or replace the control at no cost to the purchaser (or owner) other than transportation if:
- Returned within the warranty period; and
- The factory inspection finds the cause of the claim to be covered under the warranty.
- If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labor and the parts required to rebuild or replace the equipment.
- In some cases it may be expedient to ship replacement parts; or, in extreme cases a complete new control, to replace the original equipment before it is returned. If this is desired, notify the factory of both the model and serial numbers of the control to be replaced. In such cases, cred-it for the materials returned will be determined on the basis of the applicability of our warranty.
- No claims for misapplication, labor, direct or consequential damage will be allowed.
Low Voltage Directive
For use in Installations Category II, Pollution Degree 2. If equipment is used
in a manner not specified by the manufacturer, protection provided by
equipment may be impaired.
Return Material Procedure
- To efficiently process any materials that are returned, it is essential that a “Return Material Authorization” (RMA) number be obtained from the factory, prior to the material’s return. This is available through your local Magnetron representative or by contacting the factory. The following information is required:
- Company Name
- Description of Material
- Serial Number
- Reason for Return
- Application
- Any unit that was used in a process must be properly cleaned in accordance with OSHA standards, before it is returned to the factory.
- A Material Safety Data Sheet (MSDS) must accompany material that was used in any media.
- All shipments returned to the factory must be by prepaid transportation.
- All replacements will be shipped F.O.B. factory.